Morningstar SureSine 150 W User manual

Installation and Operations Manual
150 W, 300 W, & 700 W (12 V, 24 V, & 48 V) Models,
1,000 W & 1,250 W, (24 V & 48 V) Models,
2,500 W (48 V Only) Models
(120 V / 60 Hz, 230 V / 50 Hz,
127 V / 60 Hz, and 220 V / 60 Hz)
October 2022 (Rev 0 Draft 10)
MORNINGSTAR
World’s Leading Solar Controllers &Inver ters

MS-003650
MORNINGSTAR
World’s Leading Solar Controllers &Inverters
About MorningStar:
With well over 4 million products sold in over 100 countries since 1993—functioning in some of the most
extreme environments and mission-critical applications in the world—Morningstar Corporation can truly claim
to be “the leading supplier of solar controllers and inverters.” That success is why Morningstar has had staying
power and stable management for over 27 years, along with the lowest employee turnover rate.
• Smarter digital design has been pioneered for solar components, for faster, more agile processing on-
board. This allows for the maximum performance from thehardware.
• Advanced thermal engineering is used to eliminate cooling fans—the weak link in competitors’
products.
• Finally, internal electronics are laid out for performance and longevity instead of economics—designing
for the long-term in order to achieve the industry’s lowest hardware failure rates.
For additional information about Morningstar Corporation, go to:
www.morningstarcorp.com
Disclaimer:
The specifications and descriptions contained in this document are verified to be as accurate as possible at
the time of publication. However, because Morningstar Corporation’s products and their performance are
constantly evolving, Morningstar reserves the right to make product or documentation modifications at any
time, with or without notice. Due to the wide range of applications where this product can be used, details may
vary by product version, geography, and site application.
To ensure that you have the most current version of this document, go to:
www.morningstarcorp.com/support.
To communicate any inaccuracies or omissions in this document, please fill out a contact form at:
www.morningstarcorp.com/support.
Reference document #: MS-003650. Rev 0 Draft 10
Contact Information:
Morningstar Corporation
8 Pheasant Run
Newtown, Pennsylvania 18940 USA
Email: [email protected]
Website: www.morningstarcorp.com
Service and Support: www.morningstarcorp.com/support
Phone: [phone]
Copyright 2022:
This document and its contents are protected by trade secrets, patent, copyright, and other applicable laws.
Allrights are reserved. Unauthorized use is illegal.
SureSine™ is a trademark of Morningstar Corporation
MODBUS™ and MODBUS TCP/IP™ are trademarks of Modbus IDA. www.modbus-ida.org
© 2022 Morningstar Corporation. All rights reserved.

MS-003650
MORNINGSTAR
World’s Leading Solar Controllers &Inverters
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS - This manual contains important safety, installation, and operating
instructions for the Morningstar SureSine Inverter.
The SureSine produces voltages and currents capable of causing severe injury or death. Extreme
caution must be taken when installing and using the SureSine.
The following symbols are used throughout this manual to indicate potentially dangerous conditions
or important safety instructions.
WARNING: Indicates a potentially dangerous condition.
Failure to observe this notice could result in severe personal
injury ordeath.
CAUTION: Indicates a critical procedure for safe and proper
operation of the SureSine. Use extreme caution when
performing this task. Failure to observe this notice could result
in personal injury or equipment damage.
NOTE: Indicates a procedure or function that is important to
the safe and proper operation of the SureSine Inverter.
GENERAL SAFETY INFORMATION
Throughout this manual, NEC guidance has been provided in order to meet general safety
requirements and inform best installation practices. It is the installer’s responsibility to ensure that the
Installation complies with all local safety and code requirements.
• Read all of the instructions and cautions in the manual before starting the installation.
• Ensure that battery power has been disconnected BEFORE installing, servicing, or removing
the SureSine Inverter.
• Do not allow water to enter the SureSine.
• Avoid wearing jewelry while installing this equipment.
• Do not smoke near the battery bank.
• Ensure power connections remain tight to avoid excessive heating from a looseconnection.
• Recycle the battery when it is replaced.

MS-003650
MORNINGSTAR
World’s Leading Solar Controllers &Inverters
WIRE AND CABLE SAFETY
Proper wire type and size is required for all installations. Use only UL-listed Class B or Class C wire
rated for 300 volts and 75ºC or higher. Use stranded wire for the battery circuit and solid or stranded
wire for the AC and Ground circuits.
Copper wire is recommended instead of aluminum due to its ease of use, superior conductivity,
strength and thermal expansion properties.
WARNING: SHOCK HAZARD
• Installations must be performed by a qualified person trained in electrical safety
procedures (minimum qualification).
• All wiring must comply with local electric code requirements.
• Ensure all sources of input are disconnected before connecting ANYcabling.
WARNING: RISK OF FIRE
All over-current protection devices and wiring must be sized properly, in accordance with
US National Electric Code (NEC) or the local regulations of the country of installation.
WARNING: FIRE HAZARD
A risk of fire may exist if a 120 Vac power source is wired incorrectly to 120/240 Vac
panel containing multi-wire branch circuits.
MOUNTING, CLEARANCE, AND LOCATION SAFETY
WARNING: EXPLOSION/FIRE HAZARD
Do not install in a confined area where battery gases can accumulate. Battery gases can
create an explosion or fire hazard if ignited by a spark. Ensure the enclosure is ventilated
well enough to disperse any accumulated gases.
Do not install over an easily combustible surface, since the heat sink may get hot under
certain operating conditions.
CAUTION: EQUIPMENT DAMAGE
• Do not mount in zero-clearance compartment. Overheating may result. Ensure
adequate space around the components to ensure sufficient ventilation around the
equipment.
• Locate the SureSine on a surface that is protected from directsun, hightemperatures,
corrosive fumes, and water.
• Ensure the mounting surface is strong enough to support the weight of the inverter as
well as any other devices that may be attached to it. It may be necessary to reinforce
the surface with plywood to provide additional support for the equipment.

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MORNINGSTAR
World’s Leading Solar Controllers &Inverters
CAUTION: HOT SURFACE/BURN HAZARD
The SureSine inverter models 700 Watts to 2,500 W can become very hot. Install the
SureSine so that it cannot be accidentally touched by anyone or anything.
BATTERY SAFETY INFORMATION
WARNING: SHOCK HAZARD
• Servicing of batteries should be performed, or supervised, by personnel
knowledgeable about batteries, and the proper safety precautions.
• Have someone nearby to assist in case of an accident.
• Carefully read the battery manufacturer’s instructions before installing / connecting to,
or removing batteries from the SureSine Inverter.
• A battery can present a risk of electrical shock or burn from large amounts of short-
circuit current, fire, or explosion from vented gases. Observe proper precautions.
• Remove watches, rings, jewelry and other metal objects before working with
batteries.
• Use tools with insulated handles and avoid placing tools or metal objects on top
ofbatteries.
• Disconnect charging source prior to connecting or disconnecting battery terminals.
• Determine if battery is inadvertently grounded. If so, remove the source of contact
with ground. Contact with any part of a grounded battery can result in electrical
shock. The likelihood of such a shock can be reduced if battery grounds are removed
during installation and maintenance (applicable to equipment and remote battery
supplies not having a grounded supply circuit).
WARNING: RISK OF EXPLOSION
• Explosive battery gases can be present during charging. Be certain there is enough
ventilation to release the gases.
• Proper disposal of batteries is required. Do not dispose of batteries in fire. Refer to
local regulations or codes for requirements. Recycle the battery when it is replaced.
• Never smoke in the battery area.
WARNING: CORROSION HAZARD/TOXIC FUMES
• Do not open or mutilate batteries. Released electrolyte is harmful to skin and may
betoxic if inhaled.
• Be very careful when working with large lead-acid batteries. Wear eye protection and
have fresh water available in case there is contact with the battery acid.
• Wear rubber gloves and boots.
• If battery acid comes into contact with the skin, wash with soap and water. If the acid
contacts the eye, flood with fresh water and get medical attention.
• Recycle the battery when it is replaced.

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MORNINGSTAR
World’s Leading Solar Controllers &Inverters
BATTERY SAFETY INFORMATION
(Continued)
CAUTION: EQUIPMENT DAMAGE
• Ensure the battery voltage matches the DC voltage requirements of the model of
SureSine inverter to be installed.
• Ensure the battery bank consists of batteries of the same type, make and age.
• Ensure the battery electrolyte level is correct before starting charging. Do not
attempt to charge a frozen battery.
• Ensure that the charging equipment implemented in the system meets the charging
requirements for the battery bank and varied charging.
• The SureSine Low Voltage Disconnect (LVD) and Low Voltage Reconnect (LVR) presets
are generally designed for lead acid batteries. Use custom LVD and LVR settings
required for the type of battery in the system and minimum desired state of charge
(SOC). Note that some battery types may not be compatible.
CERTIFICATIONS:
North American Certifications
• Complies with UL 1741, 62109 and CSA-C22.2 No. 107.1-01
• Complies with IEC 62109-1: 2010
• Complies with FCC Article 15, Class B
• Complies with ICES-003 Issue 4, Feb 2004 (Class B)
• Complies with the US National Electrical Code
European LVD Directive:
• EN 60335-1:2002 Safety
• EN 60335-2-29:2005 Safety
• EN/IEC 62109-1:2010 Safety of Power Converters in PV Systems
• IEC/EN 62109-1, IEC/EN 62109-2, IEC/EN 61000-6-1, IEC/EN 61000-6-2, IEC/EN 61000-6-3,
IEC/EN 61000-6-4, IEC/EN 55032, IEC/EN55011
European EMC Directive:
• EN 61000-6-2:2005 EMC Immunity, Industrial Environments
• EN 55022:2007 (Class B) EMC Emissions

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World’s Leading Solar Controllers &Inverters
i
Table of Contents
1.0 Introduction................................................................................................................1
1.1 Features.................................................................................................................1
1.2 Components of the 150 W & 300 W Models ........................................................2
1.3 Components of the 700 W Models .......................................................................3
1.4 Components of the 1,000 W to 2,500 W Models .................................................4
1.5 Dimensions of the 150 W & 300 W Models ..........................................................5
1.6 Dimensions of the 700 W to 2,500 W Models.......................................................6
2.0 Installation..................................................................................................................7
2.1 Required Tools.......................................................................................................7
2.2 Additional Hardware Requirements.......................................................................7
2.3 Mounting ...............................................................................................................8
2.3.1 Safety Considerations for Mounting.........................................................9
2.3.2 Mounting Procedure...............................................................................10
2.4 Adjusting Settings ...............................................................................................11
2.4.1 DIP Switch Location................................................................................11
2.4.2 DIP Switch Configuration Options..........................................................12
2.5 Terminal Block Installation for Remote Switch or Communications Wiring.........13
2.6 Remote Switch Installation (Optional) .................................................................14
2.7 Auxiliary Power (Optional) ...................................................................................15
2.8 Inverter Wiring.....................................................................................................16
2.8.1 Terminal Torque Requirements ..............................................................16
2.8.2 Over-current Protection Requirements...................................................17
2.8.3 DC and AC Conductor Sizing Requirements..........................................18
2.8.4 Grounding and Bonding Requirements..................................................19
2.8.5 Grounding Connections .........................................................................21
2.8.6 DC Connections .....................................................................................23
2.8.7 AC Connections......................................................................................27
2.8.8 AC Wiring ...............................................................................................28
2.9 Check Wiring and Power Up ..............................................................................30
3.0 Operation .................................................................................................................30
3.1 LED Indications....................................................................................................30
3.2 AC Output Mode Switch Operation....................................................................31
3.3 Protections...........................................................................................................31
3.3.1 Low Voltage Disconnect (LVD)................................................................31
3.3.2 High Voltage Disconnect (HVD)..............................................................32
3.3.3 High Temperature Disconnect (HTD)......................................................32
3.3.4 Over Current and Short Circuit Protection (Critical Fault).......................32
4.0 Communication Options...........................................................................................33
4.1 Bluetooth.............................................................................................................34
4.1.1 To Connect the SureSine using Bluetooth..............................................34
4.1.2 SureSine Utility App................................................................................35
4.2 Ethernet (for Modbus™ TCP/IP)..........................................................................36
4.2.1 To Connect to the Internet using Modbus Protocols .............................36
4.3 EIA-485 Device Communication .........................................................................37
4.3.1 To Connect the SureSine Inverter to an EIA-485 Device........................37
4.4 USB Port ..............................................................................................................39
4.4.1 To Connect to the USB Port....................................................................39
4.5 MS-CAN (Future Feature) ....................................................................................40
4.5.1 To Connect the SureSine to another Morningstar Device......................40
4.5.2 To Connect the SureSine to a Morningstar Network..............................41

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World’s Leading Solar Controllers &Inverters
ii
5.0 Firmware Update Procedure ....................................................................................42
6.0 Specications............................................................................................................43
Appendix A: DC Battery Wire Sizing.................................................................................47
Appendix B: DC Voltage Drop Tables ...............................................................................49
B.1 Voltage Drop Chart for 75°C or 90ºC Stranded Copper Wire (Feet),
12VoltSystem.....................................................................................................49
B.2 Voltage Drop Chart for 75°C or 90ºC Stranded Copper Wire (Meters),
12VoltSystem.....................................................................................................50
Appendix C: Warranty.......................................................................................................51
C.1 Claim Procedure ..................................................................................................51
C.2 Warranty Exclusions And Limitations...................................................................51

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MORNINGSTAR
World’s Leading Solar Controllers &Inverters
iii
List of Figures
Figure 1: SureSine Inverters Series.................................................................................................1
Figure 2: SureSine Inverter Features (150 W & 300 W Models) .....................................................2
Figure 3: SureSine Inverter Features (700 W Models) ....................................................................3
Figure 4: SureSine Inverter Features (1,000 W to 2,500 W Models) ..............................................4
Figure 5: Dimensions - 150 W to 300 W Models ...........................................................................5
Figure 6: Dimensions - 700 W to 2,500 W Models ........................................................................6
Figure 7: Mounting Orientation .....................................................................................................8
Figure 8: Mounting Holes...............................................................................................................8
Figure 9: Minimum Clearance and Ventilation Requirements ........................................................9
Figure 10: DIP Switches................................................................................................................11
Figure 11: DIP Switch Configurations ..........................................................................................11
Figure 12: Terminal Block Installation ..........................................................................................13
Figure 13: Remote Switch Wiring for 150 W to 300 W Models ...................................................14
Figure 14: Remote Switch Wiring for 700 W to 2,500 W Models ................................................14
Figure 15: Auxiliary Power Terminals on 700 W to 2,500 W Models............................................15
Figure 16: Internal Grounded Neutral vs. External Grounded Neutral
(InternalNeutralGroundBondremoved) ...................................................................20
Figure 17: DC Connections on 150 W & 300 W Models with Negative Grounding....................25
Figure 18: DC Connections on 150 W & 300 W Models with Positive Grounding ......................25
Figure 19: DC Connections on 700 W to 2,500 W Models with Negative Grounding ................26
Figure 20: DC Connections on 700 W to 2,500 W Models with Positive Grounding...................26
Figure 21: AC Connections on 150 W, 300 W, & 700 W Models (with Factory Wiring) ...............27
Figure 22: AC Wiring for 150 W or 300 W Models ......................................................................29
Figure 23: AC Wiring for 700 W, 1,000 W, 1,250 W or 2,500 W Models .....................................29
Figure 24: AC Output Mode Operation and Bluetooth Activation..............................................31
Figure 25: Communication Port Locations ...................................................................................33
Figure 26: Communication using Bluetooth.................................................................................34
Figure 27: SureSine Utility App (Main Dashboard) .......................................................................35
Figure 28: Communication using Ethernet...................................................................................36
Figure 29: EIA-485/RS-232 Communications Adapter (RSC-1) ....................................................37
Figure 30: Connecting to an EIA-485 Device...............................................................................37
Figure 31: Auxiliary Power Connections (700 W, 1,000 W, 1,250 W or 2,500 W Models ONLY) .38
Figure 32: USB Port Locations......................................................................................................39
Figure 33: Communication Using MS-CAN..................................................................................40
Figure 34: Communication Using MS-CAN with Multiple Devices ..............................................41

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World’s Leading Solar Controllers &Inverters
iv
List of Tables
Table 1: DIP Switch Configuration................................................................................................12
Table 2: Low Voltage Disconnect Settings (DIP 4 & 5) .................................................................12
Table 3: Terminal Torque Requirements .......................................................................................16
Table 4: DC Battery Circuit Breaker/Fuse Size..............................................................................17
Table 5: AC Circuit Breaker/Fuse Size ..........................................................................................18
Table 6: Minimum Battery Cable Size - 75°C rated Copper.........................................................18
Table 7: Minimum AC Output Wire Size - 75°C rated Copper.....................................................19
Table 8: Minimum Wire Sizes for Copper Ground Cable .............................................................22
Table 9: LED Indications ...............................................................................................................30
Table 10: Specifications for the SureSine 150 and SureSine 300 .................................................43
Table 11: Specifications for the SureSine 700 and SureSine 1000 ...............................................44
Table 12: Specifications for the SureSine 1250 and SureSine 2500 .............................................45
Table 13: Common Specifications for all Models .........................................................................46
Table 14: Minimum Battery Wire Sizes - 75°C Rated Stranded Copper.......................................47
Table 15: Minimum Battery Wire Sizes - 90°C Rated Stranded Copper.......................................48
Table 16: Celsius-to-Fahrenheit Conversions ...............................................................................48
Table 17: Maximum 1-way Distance (Feet), 2% Voltage Drop Chart for 75°C or 90ºC
Stranded Copper Wire, 12-VoltSystem......................................................................49
Table 18: Maximum 1-way Distance (Meters), 2% Voltage Drop Chart for 75°C or 90ºC
Stranded Copper Wire, 12-VoltSystem......................................................................50